Measure the timing chain tensioner from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 2.83 inches (72 mm) front end to end. A tensioner in the active state will measure 3.35 inches (85 mm) from end to end.

If the timing chain tensioner is not in the compressed state, perform the following steps:

Remove the piston assembly from the body of the timing chain tensioner by pulling it out.

Install the bottom half of the Tensioner tool J-45027-2 into a vise.

Install the notch end of the piston assembly into the bottom half of the tensioner tool.

Using the top half of the Tensioner tool J-45027-1, turn the ratchet cylinder into the piston.

Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore.

Release the timing chain tensioner by compressing it approximately 0.08 inches (2mm). Feed a rubber-tipped tool down through the cam drive chest to reset on the cam chain. Give the tool a sharp jolt diagonally downwards to release the tensioner.

Measure the timing chain tensioner from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 2.83 inches (72 mm) front end to end. A tensioner in the active state will measure 3.35 inches (85 mm) from end to end.

If the timing chain tensioner is not in the compressed state, perform the following steps:

Remove the piston assembly from the body of the timing chain tensioner by pulling it out.

Install the bottom half of the Tensioner tool J-45027-2 into a vise.

Install the notch end of the piston assembly into the bottom half of the tensioner tool.

Using the top half of the Tensioner tool J-45027-1, turn the ratchet cylinder into the piston.

Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore.

Release the timing chain tensioner by compressing it approximately 0.08 inches (2mm). Feed a rubber-tipped tool down through the cam drive chest to reset on the cam chain. Give the tool a sharp jolt diagonally downwards to release the tensioner.

Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in alignment.

Remove or disconnect the following:

Camshaft sprocket and timing chain

Crankshaft sprocket

Timing chain damper

Fig. Timing chain and sprocket timing mark alignment

To install:

Install or connect the following:

Timing chain damper. Torque the bolts to 15 ft. lbs. (21 Nm).

Crankshaft sprocket

Be sure the crankshaft sprocket timing mark is pointing straight up.

Install the timing chain over the camshaft sprocket and hold the sprocket in such a way, that the timing mark is pointing down, and the timing chain is hanging down off the sprocket.

Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft. The sprocket will only fit on the camshaft if the dowel on the camshaft aligns with the hole in the sprocket.

Verify that the marks are aligned (the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket will be in the 12 o'clock position).

Torque the camshaft sprocket mounting bolt to 103 ft. lbs. (140 Nm).

Lubricate the timing chain components with engine oil.

Apply a thin bead of sealer around the gasket sealing area of the front cover.

Install or connect the following:

Front cover with a new seal and gasket. Torque the small bolts to 15 ft. lbs. (21 Nm) and the large bolts to 35 ft. lbs. (47 Nm).

Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in alignment.

Remove or disconnect the following:

Camshaft sprocket and timing chain

Crankshaft sprocket

Timing chain damper

Fig. Timing chain and sprocket timing mark alignment

To install:

Install or connect the following:

Timing chain damper. Torque the bolts to 15 ft. lbs. (21 Nm).

Crankshaft sprocket

Be sure the crankshaft sprocket timing mark is pointing straight up.

Install the timing chain over the camshaft sprocket and hold the sprocket in such a way, that the timing mark is pointing down, and the timing chain is hanging down off the sprocket.

Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft. The sprocket will only fit on the camshaft if the dowel on the camshaft aligns with the hole in the sprocket.

Verify that the marks are aligned (the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket will be in the 12 o'clock position).

Torque the camshaft sprocket mounting bolt to 103 ft. lbs. (140 Nm).

Lubricate the timing chain components with engine oil.

Apply a thin bead of sealer around the gasket sealing area of the front cover.

Install or connect the following:

Front cover with a new seal and gasket. Torque the small bolts to 15 ft. lbs. (21 Nm) and the large bolts to 35 ft. lbs. (47 Nm).